I broke off my Oxygen sensor

In the process of trying to replace my O2 (Oxygen) sensor on my 1993
honda civic EX, I broke the old one off. I tried some usual stuff,
knocking it with a hammer, liberal WD-40, running the car for a bit to
heat up the manifold. Anyway, TINK! it broke. Any suggestions?

Two pictures of the sensor and manifold
http://img416.imageshack.us/my.php?image=exhaustmanifold7eh.jpg
http://img416.imageshack.us/my.php?image=o2sensor9it.jpg

 

First of all, WD-40 is not a penetrating oil, claims to the contrary by
the manufacturer and thousands of users notwithstanding. It's a little
late now, but really, you should have used Kroil, PB Blaster, or one of
the other purpose-made penetrating oils rather than WD-40. Guess you
will remember that next time :/

Now as to your immediate situation - that sucker is broken off in a very
difficult way. I would personally suggest, if you have access, dropping
the downpipe so the bottom of the manifold is open, and then trying to
drill it out with successively larger drill bits. If you are lucky the
drill bit will "catch" and spin the remaining piece out into the
manifold (this is why I suggested dropping the downpipe.) If you are
less than lucky, you'll end up drilling it out to the threads, in which
case a spark plug thread chaser tap should clean them up.

You may find it easier to remove the manifold from the car; I haven't
ever worked on a Honda so I don't know how difficult access is vs.
manifold removal.

Needless to say, put some anti-seize on the threads of the new O2
sensor, and next time you go to replace one, before you get to the point
of breakage, try heating the manifold around the sensor with a torch,
pref. oxyacetylene if you have access to one.

good luck,

nate

 

First of all, WD-40 is not a penetrating oil, claims to the contrary by
the manufacturer and thousands of users notwithstanding. It's a little
late now, but really, you should have used Kroil, PB Blaster, or one of
the other purpose-made penetrating oils rather than WD-40. Guess you
will remember that next time :/

Now as to your immediate situation - that sucker is broken off in a very
difficult way. I would personally suggest, if you have access, dropping
the downpipe so the bottom of the manifold is open, and then trying to
drill it out with successively larger drill bits. If you are lucky the
drill bit will "catch" and spin the remaining piece out into the
manifold (this is why I suggested dropping the downpipe.) If you are
less than lucky, you'll end up drilling it out to the threads, in which
case a spark plug thread chaser tap should clean them up.

You may find it easier to remove the manifold from the car; I haven't
ever worked on a Honda so I don't know how difficult access is vs.
manifold removal.

Needless to say, put some anti-seize on the threads of the new O2
sensor, and next time you go to replace one, before you get to the point
of breakage, try heating the manifold around the sensor with a torch,
pref. oxyacetylene if you have access to one.

good luck,

nate

 

Liquid Wrench penetrating oil. Soak repeatedly. Then pull all the
garbage out of the center of the O2 sensor that is still in the
manifold, and use an EZ OUT, or just drill the sucker with a large
drill bit until it spins off on its own.

Lg

WD 40 is $hit in a can.

 

Liquid Wrench penetrating oil. Soak repeatedly. Then pull all the
garbage out of the center of the O2 sensor that is still in the
manifold, and use an EZ OUT, or just drill the sucker with a large
drill bit until it spins off on its own.

Lg

WD 40 is $hit in a can.

 

Or you can also use a pipe tool that when you turn it counterclockwise,
will grab the inside of whatever is left in there and will come out. I had
a similar problem with my lawn tractor.... the drain pipe for the oil was
way too short and wanted to lenghten it. Well somehow, it broke off right at
the edge of the engine block and I used one of those pipe tools that goes
inside. I got it at home repo (depot) for not too much.

Good Luck,

Fwed

 

Or you can also use a pipe tool that when you turn it counterclockwise,
will grab the inside of whatever is left in there and will come out. I had
a similar problem with my lawn tractor.... the drain pipe for the oil was
way too short and wanted to lenghten it. Well somehow, it broke off right at
the edge of the engine block and I used one of those pipe tools that goes
inside. I got it at home repo (depot) for not too much.

Good Luck,

Fwed

 

yeesh. some options, in no particular order-

junkyard manifold
new manifold
new header
take it to a machine shop- let them get it out and rethread it
you drill it out/rethread it
hammer big flathead screwdriver into it, try to turn
judicious use of an air chisel, big flathead, try to turn

 

yeesh. some options, in no particular order-

junkyard manifold
new manifold
new header
take it to a machine shop- let them get it out and rethread it
you drill it out/rethread it
hammer big flathead screwdriver into it, try to turn
judicious use of an air chisel, big flathead, try to turn

 

Hmm, I've never seen what you're describing, but it sounds like
something to add to the bag o' tricks. Is this a plumbing tool? I will
have to look next time I'm at Home Despot.

nate

PS - I have never had any luck with EZ-outs. They always seem to break
on me.

 

Hmm, I've never seen what you're describing, but it sounds like
something to add to the bag o' tricks. Is this a plumbing tool? I will
have to look next time I'm at Home Despot.

nate

PS - I have never had any luck with EZ-outs. They always seem to break
on me.

 

Excellent idea. LEVERAGE IS YOUR FRIEND. Long handles are in
fashion.


Lg

 

Excellent idea. LEVERAGE IS YOUR FRIEND. Long handles are in
fashion.


Lg

 

Might try a radial cut with a small hacksaw blade.

 

Might try a radial cut with a small hacksaw blade.

 

That's what I had to do with my 40 year old bathtub drain. I had to
make 2 cuts, one on each side, about 120 degrees apart from eachother,
and then the entire affair collapsed in on itself with a little help
from a screwdriver and a hammer.

 

That's what I had to do with my 40 year old bathtub drain. I had to
make 2 cuts, one on each side, about 120 degrees apart from eachother,
and then the entire affair collapsed in on itself with a little help
from a screwdriver and a hammer.

 

Because I have to *anneal* mine first, the big ones, by heating with a
propane tourch and then letting them air cool. It takes the
brittleness out of them.

Lg

 

Because I have to *anneal* mine first, the big ones, by heating with a
propane tourch and then letting them air cool. It takes the
brittleness out of them.

Lg

 

Yes, they are sold at home depot....when i had this problem, i didn't
know what to do either until I went there and started asking around..... one
of the people there showed me it....and told me it works wonders...forgot
how much it is, but I don't think it was too much.... it comes in three
sizes....well the one i have did...

good luck,

Fwed